System and method to control the operation of a transmission using engine fuel consumption data

ABSTRACT

A system and method of controlling the operation of a transmission using fuel consumption data. The system and method includes controlling the operation of a vehicle transmission which is operatively connected to an engine having operating characteristics and operatively connected to a transmission control module having access to a memory. Fuel consumption data for an engine is converted to engine efficiency loss data representative of the engine operating. A set of polynomials is determined to provide a pattern representative of the operating characteristics the engine. A transmission controller using the pattern determines a prospective operating condition of the transmission to provide fuel efficient operation of the engine.

CROSS-REFERENCE TO RELATED APPLICATION

U.S. Patent Application entitled “System and Method to Control theOperation of a Transmission Using Engine Patterns” filed on Dec. 3, 2015is incorporated by reference herein in its entirety.

FIELD OF THE DISCLOSURE

The present disclosure relates to a multiple speed transmission, andmore particularly to controlling the operation of a multiple speedtransmission using engine fuel consumption data.

BACKGROUND

In a vehicle, a prime mover drives a set of wheels, or other groundengaging traction devices, which engages a support surface, such as aroad or ground, to move the vehicle. Because the output of the primemover, which includes engines and/or motors, must adapt to differentspeed requirements and road conditions, a transmission is locatedbetween the prime mover and a set of wheels to adjust the output of theprime mover in order to move the vehicle at different speeds. Thetransmission includes an input shaft, operatively connected to an outputshaft of the prime mover, and an output shaft, operatively connected toa drivetrain connected to the wheels.

The transmission is configured to transmit power and torque from theengine to the drive train. In one type of conventional transmission, thetransmission includes a variety of gears, shafts, and clutchesconfigured to transmit torque through the transmission at finite,stepped gear ratios. Multiple speed transmissions use a number offriction clutches or brakes, planetary gearsets, shafts, and otherelements to achieve a plurality of gear or speed ratio. In another typeof transmission, a continuously variable transmission (CVT) isconfigured to continuously vary the ratio of an input rotational speedto an output rotational speed under control of a vehicle operator,typically by a speed controller input such as provided by a throttle.

Different engines are designed to have varying capabilities at differentoperating ranges, and are optimized for different conditions based onthe engine manufacturer's designed operating characteristics. Thesedifferent capabilities and characteristics are captured in fuelconsumption values, which engine manufactures typically provide to apurchaser of the engine, such as a vehicle manufacturer or transmissionmanufacturer. In the case of a transmission manufacturer, the fuelconsumption data provides data which can be useful in determining when atransmission shift operation should be made to achieve fuel efficientoperation of the engine. Even though the provided fuel consumption dataprovides useful information for the purchaser, the fuel consumptionvalues do not readily provide engine efficiency characteristics acrossan engine's speed and torque output. In addition, the format of the fuelconsumption data is not consistent between one engine manufacturer andanother engine manufacturer. Consequently, what is needed is a systemand method for utilizing engine fuel consumption data to modify theoperation of a transmission and to operate the engine efficiently.

SUMMARY

In one embodiment of the present disclosure, there is provided a methodof controlling the operation of a vehicle transmission operativelyconnected to an engine having operating characteristics and operativelyconnected to a transmission control module having access to a memory.The method includes receiving fuel consumption data for an engine,converting the fuel consumption data for the engine to engine efficiencyloss data representative of the engine operating characteristics,generating a set of polynomials to characterize the engine efficiencyloss data, and generating a set of the set of polynomials, wherein theset of polynomials represents the operating characteristics the engine.The method further includes storing the set of polynomials in thememory, accessing the set of polynomials stored in memory with thetransmission control module, and using the accessed set of polynomialsto modify the operation of the transmission based on the operatingcharacteristics of the engine.

In another embodiment, there is provided a transmission systemconfigured to drive a drive assembly of a vehicle in response to anengine output shaft of an engine responding to a throttle command. Thetransmission assembly includes a transmission including an inputconfigured to be coupled to the engine output shaft and an outputconfigured to drive the drive assembly, a memory configured to store oneor more engine patterns, wherein each of the one or more stored enginepatterns includes a plurality of polynomials and further wherein theplurality of polynomials represents the operating characteristics of theengine. A transmission controller is operatively coupled to thetransmission and to the memory. The transmission controller isconfigured to execute stored program instructions to: determine at leastone of engine speed and engine torque from the received throttlecommand; determine a current operating condition of the transmission;access the memory to retrieve one of the one or more stored enginepatterns; determine an updated operating condition of the transmissionusing the accessed engine pattern and the determined at least one of theengine speed and the engine torque; and modify the current operatingcondition of the transmission to an updated operating state of thetransmission based on the determined updated operating condition of thetransmission.

BRIEF DESCRIPTION OF THE DRAWINGS

The above-mentioned aspects of the present disclosure and the manner ofobtaining them will become more apparent and the disclosure itself willbe better understood by reference to the following description of theembodiments of the disclosure, taken in conjunction with theaccompanying drawings, wherein:

FIG. 1 is a block diagram of one embodiment of a powered vehicularsystem;

FIG. 2 is a graph representing fuel consumption data for an engineshowing fuel consumption versus engine speed at a plurality of differentengine torque outputs.

FIG. 3 is a block diagram of a process to determine a patternrepresentative of the fuel consumption data of an engine using a set ofpolynomials;

FIG. 4 is a graph representing engine efficiency loss data (EEL) of anengine showing engine torque versus engine speed;

FIG. 5 is a graph representing scaled EEL values versus scaled torquewith respect to engine speed.

FIG. 6 is a schematic representation of a plurality of engine patternseach representative of the fuel consumption data of an engine.

FIG. 7 is a block diagram of a process to control the operation of atransmission using an engine pattern.

Corresponding reference numerals are used to indicate correspondingparts throughout the several views.

DETAILED DESCRIPTION

The embodiments of the present disclosure described below are notintended to be exhaustive or to limit the disclosure to the preciseforms disclosed in the following detailed description. Rather, theembodiments are chosen and described so that others skilled in the artmay appreciate and understand the principles and practices of thepresent disclosure.

Referring now to FIG. 1, a block diagram and schematic view of oneillustrative embodiment of a vehicular system 100 having an engine 102and an automatic transmission 118 is shown. In the illustratedembodiment, the engine 102 may include an internal combustion engine,diesel engine, or other fuel power-generating devices. The engine 102 isconfigured to rotatably drive an output shaft 104 that is coupled to aninput or pump shaft 106 of a conventional torque converter 108. Theinput or pump shaft 106 is coupled to an impeller or pump 110 that isrotatably driven by the output shaft 104 of the engine 102. The torqueconverter 108 further includes a turbine 112 that is coupled to aturbine shaft 114, and the turbine shaft 114 is coupled to, or integralwith, a rotatable input shaft 124 of the transmission 118. Thetransmission 118 can also include an internal pump 120 for buildingpressure within different flow circuits (e.g., main circuit, lubecircuit, etc.) of the transmission 118. The pump 120 can be driven by ashaft 116 that is coupled to the output shaft 104 of the engine 102. Inthis arrangement, the engine 102 can deliver torque to the shaft 116 fordriving the pump 120 and building pressure within the different circuitsof the transmission 118.

The transmission 118 can include a planetary gear system 122 having anumber of automatically selected gears. An output shaft 126 of thetransmission 118 is coupled to or integral with, and rotatably drives, apropeller shaft 128 that is coupled to a conventional universal joint130. The universal joint 130 is coupled to, and rotatably drives, anaxle 132 having wheels 134A and 134B mounted thereto at each end. Theoutput shaft 126 of the transmission 118 drives the wheels 134A and 134Bin a conventional manner via the propeller shaft 128, universal joint130 and axle 132.

A conventional lockup clutch 136 is connected between the pump 110 andthe turbine 112 of the torque converter 108. The operation of the torqueconverter 108 is conventional in that the torque converter 108 isoperable in a so-called “torque converter” mode during certain operatingconditions such as vehicle launch, low speed and certain gear shiftingconditions. In the torque converter mode, the lockup clutch 136 isdisengaged and the pump 110 rotates at the rotational speed of the driveunit output shaft 104 while the turbine 112 is rotatably actuated by thepump 110 through a fluid (not shown) interposed between the pump 110 andthe turbine 112. In this operational mode, torque multiplication occursthrough the fluid coupling such that the turbine shaft 114 is exposed todrive more torque than is being supplied by the engine 102, as is knownin the art. The torque converter 108 is alternatively operable in aso-called “lockup” mode during other operating conditions, such as whencertain gears of the planetary gear system 122 of the transmission 118are engaged. In the lockup mode, the lockup clutch 136 is engaged andthe pump 110 is thereby secured directly to the turbine 112 so that thedrive unit output shaft 104 is directly coupled to the input shaft 124of the transmission 118, as is also known in the art.

The transmission 118 further includes an electro-hydraulic system 138that is fluidly coupled to the planetary gear system 122 via a number,J, of fluid paths, 140 ₁-140 _(J), where J may be any positive integer.The electro-hydraulic system 138 is responsive to control signals toselectively cause fluid to flow through one or more of the fluid paths,140 ₁-140 _(J), to thereby control operation, i.e., engagement anddisengagement, of a plurality of corresponding friction devices in theplanetary gear system 122. The plurality of friction devices mayinclude, but are not limited to, one or more conventional brake devices,one or more torque transmitting devices, and the like. Generally, theoperation, i.e., engagement and disengagement, of the plurality offriction devices is controlled by selectively controlling the frictionapplied by each of the plurality of friction devices, such as bycontrolling fluid pressure to each of the friction devices. In oneexample embodiment, which is not intended to be limiting, the pluralityof friction devices include a plurality of brake and torque transmittingdevices in the form of conventional clutches that may each becontrollably engaged and disengaged via fluid pressure supplied by theelectro-hydraulic system 138. In any case, changing or shifting betweenthe various gears of the transmission 118 is accomplished in aconventional manner by selectively controlling the plurality of frictiondevices via control of fluid pressure within the number of fluid paths140 ₁-140 _(J).

The system 100 further includes a transmission controller 142, ortransmission control module, that includes a memory unit 144 accessiblyby the transmission controller in one embodiment. In other embodiments,the memory unit is separately located from the transmission controller.The transmission controller 142 is illustratively microprocessor-based,and the memory unit 144 generally includes instructions stored thereinthat are executable by a processor of the transmission controller 142 tocontrol operation of the torque converter 108 and operation of thetransmission 118, i.e., shifting between the various gears of theplanetary gear system 122. It will be understood, however, that thisdisclosure contemplates other embodiments in which the transmissioncontroller 142 is not microprocessor-based, but is configured to controloperation of the torque converter 108 and/or transmission 118 based onone or more sets of hardwired instructions and/or software instructionsstored in the memory unit 144.

In the system 100 illustrated in FIG. 1, the torque converter 108 andthe transmission 118 include a number of sensors configured to producesensor signals that are indicative of one or more operating states oroperating conditions of the torque converter 108 and transmission 118,respectively. For example, the torque converter 108 illustrativelyincludes a conventional speed sensor 146 that is positioned andconfigured to produce a speed signal corresponding to the rotationalspeed of the pump shaft 106, which is the same rotational speed of theoutput shaft 104 of the engine 102. The speed sensor 146 is electricallyconnected to a pump speed input, PS, of the transmission controller 142via a signal path 152, and the transmission controller 142 is operableto process the speed signal produced by the speed sensor 146 in aconventional manner to determine the rotational speed of the turbineshaft 106/drive unit output shaft 104.

The transmission 118 illustratively includes another conventional speedsensor 148 that is positioned and configured to produce a speed signalcorresponding to the rotational speed of the transmission input shaft124, which is the same rotational speed as the turbine shaft 114. Theinput shaft 124 of the transmission 118 is directly coupled to, orintegral with, the turbine shaft 114, and the speed sensor 148 mayalternatively be positioned and configured to produce a speed signalcorresponding to the rotational speed of the turbine shaft 114. In anycase, the speed sensor 148 is electrically connected to a transmissioninput shaft speed input, TIS, of the transmission controller 142 via asignal path 154, and the transmission controller 142 is operable toprocess the speed signal produced by the speed sensor 148 in aconventional manner to determine the rotational speed of the turbineshaft 114/transmission input shaft 124.

The transmission 118 further includes yet another speed sensor 150 thatis positioned and configured to produce a speed signal corresponding tothe rotational speed of the output shaft 126 of the transmission 118.The speed sensor 150 may be conventional, and is electrically connectedto a transmission output shaft speed input, TOS, of the transmissioncontroller 142 via a signal path 156. The transmission controller 142 isconfigured to process the speed signal produced by the speed sensor 150in a conventional manner to determine the rotational speed of thetransmission output shaft 126.

In the illustrated embodiment, the transmission 118 further includes oneor more actuators configured to control various operations within thetransmission 118. For example, the electro-hydraulic system 138described herein illustratively includes a number of actuators, e.g.,conventional solenoids or other conventional actuators, that areelectrically connected to a number, J, of control outputs, CP₁-CP_(J),of the transmission controller 142 via a corresponding number of signalpaths 72 ₁-72 _(J), where J may be any positive integer as describedabove. The actuators within the electro-hydraulic system 138 are eachresponsive to a corresponding one of the control signals, CP₁-CP_(J),produced by the transmission controller 142 on one of the correspondingsignal paths 72 ₁-72 _(J) to control the friction applied by each of theplurality of friction devices by controlling the pressure of fluidwithin one or more corresponding fluid passageway 140 ₁-140 _(J), andthus control the operation, i.e., engaging and disengaging, of one ormore corresponding friction devices, based on information provided bythe various speed sensors 146, 148, and/or 150.

The friction devices of the planetary gear system 122 are illustrativelycontrolled by hydraulic fluid which is distributed by theelectro-hydraulic system in a conventional manner. For example, theelectro-hydraulic system 138 illustratively includes a conventionalhydraulic positive displacement pump (not shown) which distributes fluidto the one or more friction devices via control of the one or moreactuators within the electro-hydraulic system 138. In this embodiment,the control signals, CP₁-CP_(J), are illustratively analog frictiondevice pressure commands to which the one or more actuators areresponsive to control the hydraulic pressure to the one or morefrictions devices. It will be understood, however, that the frictionapplied by each of the plurality of friction devices may alternativelybe controlled in accordance with other conventional friction devicecontrol structures and techniques, and such other conventional frictiondevice control structures and techniques are contemplated by thisdisclosure. In any case, however, the analog operation of each of thefriction devices is controlled by the controller 142 in accordance withinstructions stored in the memory unit 144.

In the illustrated embodiment, the system 100 further includes an enginecontroller 160 having an input/output port (I/O) that is electricallycoupled to the engine 102 via a number, K, of signal paths 162, whereinK may be any positive integer. In one embodiment, the engine controller160 includes a memory unit 163 or has access to a memory. The enginecontroller 160 is operable to control and manage the overall operationof the engine 102. A throttle 161 is operatively connected to thecontroller 160 and provides a desired engine speed input to thecontroller 161 to adjust the output speed of the drive unit. In otherembodiments, the engine speed input is provided by the controller 160 asa cruise control generated drive unit speed. The engine controller 160further includes a communication port, COM, which is electricallyconnected to a similar communication port, COM, of the transmissioncontroller 142 via a number, L, of signal paths 164, wherein L may beany positive integer. The one or more signal paths 164 are typicallyreferred to collectively as a data link. Generally, the enginecontroller 160 and the transmission controller 142 are operable to shareinformation via the one or more signal paths 164 in a conventionalmanner. In one embodiment, for example, the engine controller 160 andtransmission controller 142 are operable to share information via theone or more signal paths 164 in the form of one or more messages inaccordance with a society of automotive engineers (SAE) J-1939communications protocol, although this disclosure contemplates otherembodiments in which the engine controller 160 and the transmissioncontroller 142 are operable to share information via the one or moresignal paths 164 in accordance with one or more other conventionalcommunication protocols (e.g., from a conventional databus such as J1587data bus, J1939 data bus, IESCAN data bus, GMLAN, Mercedes PT-CAN). Inaddition, a Hardwire TPS (throttle position sensor) to transmissioncontroller or Hardwire PWM (pulse width modulation) to transmissioncontroller can be used.

Transmission shift schedules and other related instructions are includedin software which is downloaded to the transmission controller 142. Inother embodiments, the transmission controller 142 is preprogrammed. Thetransmission controller 142 controls the shifting of the transmission byelectrically transferring instructions to the transmission such thatcertain actions are carried out by the synchronizers, brakes, clutches,dog clutches, pistons, etc. In one non-limiting embodiment, thetransmission controller 142 is part of a transmission control circuitthat can further include an electronic solenoid and valve assembly forcontrolling the engaging and disengaging of clutch assemblies, etc.Components within the transmission 118 are activated electrically,mechanically, hydraulically, pneumatically, automatically,semi-automatically, and/or manually. The transmission controller circuitis able to control the operation of the transmission to achieve desiredperformance.

Based on instructions in a transmission software program, thetransmission control circuit (e.g., transmission controller 142)determines a shift schedule depending on a vehicle's driving conditionand executes instructions contained in the software by sending signalsthrough to control the transmission 118. The transmission controller142, in different embodiments, also receives measurement data from thetransmission 118 such as, for example, input speed from the input speedsensor 146 and output speed from the output speed sensor 130. In oneembodiment in which the transmission does not include a torqueconverter, the transmission may only have an input speed sensor 146 andoutput speed sensor 150. The transmission controller 142, in differentembodiments, also calculates various parameters including transmissiongear ratios or ranges, which depend on the ratio of input speed tooutput speed.

The transmission controller 142, in different embodiments, receivesaccelerator pedal position (i.e., throttle percentage) from a throttleinput source, for example throttle 161, which, in different embodiments,is coupled to the engine controller 160 or vehicle control module (notshown) for transmitting throttle data over the data bus.

Information such as accelerator pedal position that is communicated overthe data bus is not limited to a particular engine/transmissionconfiguration. Instead, the data bus can be adapted to most vehiclesetups.

The transmission controller 142 is operatively connected to thetransmission 118 through the described sensors and data bus. The engine102 is operatively connected to the engine controller 160, also known asan engine control module (ECM) to control the engine 102. The enginecontroller 160 may be further connected to various sensors of thevehicle that provide the engine controller 160 with various operatingconditions associated with operation of the engine 102.

The transmission 118, in different embodiments, is configured to providea torque-speed conversion from the generally higher speed engine 102 toa slower but more forceful output to the drive assembly including thepropeller shaft 128. The drive assembly, in different embodiments,includes drive wheels, caterpillar tracks, ground engaging tractiondevices, etc. that moves the motor vehicle when driven by the engine 102via the transmission 118.

The engine controller 160 and transmission controller 142, in differentembodiments, are implemented using analog and/or digital circuitcomponents. In one embodiment, the engine controller 160 and thetransmission controller 142 each include a processor, such as amicrocontroller or microprocessor. Furthermore, the engine controller160 and transmission controller 142 each have one or more associatedmemory devices 144, 163 configured to store instructions to berespectively executed by the engine controller 160 and the transmissioncontroller 142. The memory devices 144, 163 in different embodiments,include programmable read only memory devices, flash memory devices,random access memory devices, and/or other storage devices that storeinstructions to be executed and data to be processed by the enginecontroller 160 and the transmission controller 142.

Fuel powered engines have varying capabilities at different operatingranges, and are optimized for different conditions based on themanufacturer's and the customer's intended applications. Each differenttype of engine is characterized by the manufacturer, and thesecharacteristics are provided to the customer as engine fuel consumptiondata. In some cases, the engine fuel consumption data does not cover theentire range of engine operating characteristics. In other cases, thefuel consumption data is not provided, has not been updated, or is notavailable. The engine fuel consumption data is generally consistent foreach engine of the same type, but different engines of different typeshave different fuel consumption data characteristics. In each instanceof fuel consumption data, however, fuel consumption values increase withincreasing torque and speed. In one example illustrated in FIG. 2, forinstance, as the engine speed increases, the fuel consumed alsoincreases. The graph of FIG. 2 also illustrates that the torque providedby the engine generally increases while engine speed and fuelconsumption increase up to a certain value of fuel consumption andengine speed, at which point the torque levels off and no longerincreases.

The engine fuel consumption data, while helpful for determining theoperating characteristics of an engine, does not always provide thenecessary information to optimize the operation of a transmissionresponding to the rotational torque developed by an engine. In addition,the engine fuel consumption data generated by different enginemanufacturers is not represented in a standardized format which can beconsistently used by a transmission manufacturer which providestransmissions to a wide variety of vehicle manufactures using differentengines. For instance, some engine manufacturers provide the engine fuelconsumption data as brake specific fuel consumption data in units ofliters per kilowatt hour. Brake specific fuel consumption data isdetermined by the rate of fuel consumption divided by the powerproduced. As can be seen, therefore, a transmission manufacturer must beable to design a transmission which accommodates a large number ofdifferent types of engines. Unfortunately, however, the engine fuelconsumption data provided by an engine manufacturer is not in a formwhich is readily used by a transmission manufacture. The engine fuelconsumption data is not only data intensive, but is also not configuredto provide the information in a fashion which is efficiently used duringtransmission operation.

FIG. 3 illustrates a block diagram 200 of a process to reduce orcompress engine fuel consumption data to a representative model of theengine operating characteristics embodied as a pattern or map which isstored in the memory 144 for use by the transmission controller. Inother embodiments, one or more other memories accessible to thetransmission controller 142 are used. The transmission controller 142accesses the memory 144 during transmission operations to efficientlydrive a vehicle drive train in response to engine speed, engine torque,or vehicle speed, or other engine operating conditions which thetransmission converts to a transmission output torque provided attransmission output shaft 126. To compress engine fuel consumption datato a pattern, a set of fuel consumption data for one or more engines isreceived from one or more engine manufacturers at block 202. In otherembodiments, the manufacturer for the engine and transmission areprovided by the same company. In other configurations, the enginemanufacturer is a different company than the company manufacturing thetransmission. Once received, each set of fuel consumption data isconverted to data representative of torque values with respect to engineefficiency loss values at block 204. The engine efficiency loss valuesare generated for any speed or torque values for the engine beingdefined. Please see FIG. 4 for one example of engine efficiency lossvalues (EEL).

Each engine is therefore characterized as having an EEL pattern whichprovides engine operating characteristics of engine torque versus enginespeed with EEL lines 205. Each of the lines 205 illustrates a single EELvalue which is a consistent value along the continuous line plottedagainst engine torque and engine speed. Consequently, each of the EELlines 205 illustrates a different value of engine efficiency loss.

An EEL value provides a measure of the variance of fuel consumption,with respect to the most efficient operating point. The loss valuesindicate a loss in engine power over the operating range of the engineand therefore indicate the engine operating conditions which are themost efficient operating conditions. The engine efficiency loss valueis, therefore, determined as being a fuel consumption efficiency ratio,α, minus the power provided for each of the provided engine fuelconsumption data points.Engine Efficiency Loss=α−Power

In one embodiment, the EEL value is provided in kilowatts. By convertingthe engine fuel consumption data for each engine to corresponding engineefficiency loss values, a normalized set of operating characteristicsfor each engine is provided. By providing a normalized set of operatingcharacteristics for each engine, the operation of one type oftransmission is efficiently controlled when engines of different typesare used with the one type of transmission.

Engine power is an integral part of the EEL calculation. To provide astandardized set of data for each engine so that operatingcharacteristics of different engines are comparable with respect to eachother, the engine power of one engine is scaled to match another powerrange of a different engine having a potentially different speed andtorque range. By scaling engine power, the EEL values calculated by apattern definition are consistent with different torques and speeds. Inorder to properly scale the patterns, the torque and speed ranges arescaled based on the operating ranges from each pattern. Consequently,the torque range for each engine is scaled from zero (0) to the peaktorque of the engine. Therefore, in order to scale torque between thepattern definition and another peak torque, the following equation isused to determine the scaled torque factor.

${TrqScaled} = \frac{{PeakTrq}_{B}}{{PeakTrq}_{Pattern}}$

Where: TrqScaled=Scaled Torque Factor; PeakTrqB=Peak Torque of the othertorque range (units of newton meters); and PeakTrq_(Pattern)=Peak Torqueof the Engine on which the EEL pattern is based (units of newtonmeters).

Once the torque values for each of the EEL calculations are determined,scaling of the range of speeds experienced by an engine is determinedfor each engine. The speed scaling factor is based on three maincomponents, or “ratios”, that are ratios of the two different speedranges. (One speed range is from the minimum to the maximum operatingspeed of the engine which was used to develop the pattern and the otherspeed range is from the minimum to the maximum operating speed forwhatever other engine currently being evaluated by using the samepattern.) One ratio is the maximum operating speed from the patternengine to a set minimum speed. A second ratio is the maximum operatingspeed from the engine being evaluated using the pattern to evaluate tothe same set minimum speed. The third ratio is the more complex one thatrelates the current engine speed to the minimum operating speed from thepattern and the maximum operating speed of the engine you're evaluatingto the minimum operating speed from the pattern. The overall speedscaling factor combines these three ratios in the equation for SpdScaledas described below.

The scaling of speed ranges introduces complexities because of thepossibility of a large number of different operating ranges for anengine. The scaling of speed ranges is therefore made, in oneembodiment, to avoid the introduction of an error which could result ifthe scaling factor is calculated to be zero (0) or a negative number.The speed scaling factor is, therefore, based on a ratio of thedifferent minimum and maximum operating points for both the pattern, andthe other operating range.

${SpdScaled} = {1 + {\frac{\alpha\left( {R_{B} - R_{Pattern}} \right)}{\left( {1 - \alpha} \right) + {\alpha\; R_{Pattern}}}\mspace{14mu}{with}}}$$R = {{\frac{{Max}\mspace{14mu}{Speed}}{{Min}\mspace{14mu}{Speed}_{{set}\;}}\mspace{14mu}{and}\mspace{14mu}\alpha} = \frac{{Speed}_{Calc} - {Speed}_{{Pattern}\mspace{14mu}{Mi}\; n}}{{Speed}_{HSG} - {Speed}_{{Pattern}\mspace{14mu}{Mi}\; n}}}$

Where: SpdScaled=Scaled Speed Factor, α=Speed ratio based the otherengine range's high speed governor (Speed_(HSG)), minimum speed on whichthe EEL pattern is based (Speed_(Pattern Min)), and the speed at whichthe EEL value is to be calculated (Speed_(Calc)); R_(B)=Ratio valuebased on the other engine range's high speed governor and a set speedvalue above which the EEL calculation will be allowed; andR_(Pattern)=Ratio value based on the maximum speed on which the EELpattern is based and a set speed value above which the EEL calculationwill be allowed.

The overall power scaling factor is then the speed and torque scalingfactors multiplied together. This calculated factor enables thecomparison between EEL values for each different engine having torqueand speed ranges on which the pattern is based. Once EEL values havebeen calculated for the engine, the next step is to scale the torque andEEL values to a 0-1 scale. By scaling the EEL values, succeedingcalculations to provide the functions used to calculate EEL values basedon this engine pattern and any torque value have a reduce complexity,and therefore require fewer data manipulations. Calculated EEL valuesthat are based on negative torques are not used, in one embodiment, increating the pattern. The 0-1 torque scale includes torque values of 0or 1 Nm up to the torque limit for the engine. The maximum EEL value,before scaling to 1, is to be saved as a scaling factor for the specificpattern. These steps are completed to scale the torque values and theassociated engine efficient loss values for each engine for a zero toone scale as shown at block 206 of FIG. 3.

Once the EEL values have been scaled, a plurality or set of polynomialsis generated for the varying EEL values and torque values for lines ofconstant speed at block 208 of FIG. 3. Scaled EEL values have aparabolic or cubic relationship with scaled torque values for any givenspeed range as illustrated in FIG. 5. The major portion of an EELpattern is the coefficients that make up these polynomials. In oneembodiment, the process for generating the polynomials of EEL valuesversus torque is to analyze the data with data plotting software such ascurve fitting software, including non-linear curve fitting software. Inone embodiment, a trend line calculation function available in asoftware package known as Excel, available from Microsoft Corporation,Redmond, Wash., is used.

As described herein, negative torques, in one embodiment, are notincorporated in pattern definitions or calculations of the polynomials.The polynomials are determined to represent the actual EEL values overthe entire operating range of the engine.

In an embodiment incorporating EEL values from negative torque rangesinto the polynomial calculations results in vastly differentpolynomials, that are not able to acceptably and accurately reproduceEEL values for the an engine's entire operating range. Consequently, inanother embodiment, the overall shape and pattern of EEL values is todetermine polynomials having only positive torque values. In otherembodiments, however, EEL values for negative torques are predictedsufficiently accurately by linearly increasing the projected values for0 Nm torque. In other embodiments, the more negative a torque the worsethe torque's efficiency should be, so having a simple linear increase oflow torque values can provide accurate results.

Once a set of polynomials has been generated to characterize thetorque/engine efficiency values for an engine, a reduced set ofpolynomials is generated at block 210 of FIG. 3. In one embodiment, thenumber of speed polynomials is reduced to seven, while stillrepresenting the full speed range of the engine. Reducing the number ofrepresentative polynomials to seven has been shown to maintain theintegrity of engine efficiency loss values calculated while condensingthe amount of data to be stored in memory. In one embodiment, the firstpolynomial represents the lowest engine speed. The last polynomial, orseventh polynomial in this embodiment, represents the highest enginespeed, with the other five polynomials spaced evenly throughout theengine's operating range. The number of polynomials is selected based ona study conducted with simulations running the same engine patterngenerated with a variety of number of polynomials representing thatpattern. In this embodiment, the seven polynomials are sufficient tocalculate the EEL values with minimal degradation in fuel economy. Inother embodiments, however, the number of polynomials selected is more,or less, than seven. The number of polynomials is selected based on thedesired accuracy of reconstructed engine data using the polynomials, theamount of memory available for storing the polynomials, and the speed ofpolynomial calculations provided by the transmission controller. Thepresent disclosure, however, is not limited to patterns having a numberof polynomials, and other data abstraction representations of anengine's fuel consumption data are included.

The results of each of the representative (reduced set) polynomialequations does not always provide the same result when compared to theresult if the originally derived polynomials are used. The results usingthe reduced set of polynomials, however, provide values which aresufficient to effectively and efficiently operate a transmission system.Because the set of seven polynomial equations represents the entireoperating range of the engine, the polynomial equations are able toreproduce all of the engine efficiency loss values, with an acceptableamount of error.

In one example, a software program known as MATLAB® available fromMathworks, Natick, Mass., is used to generate a reduced set ofpolynomial equations having a minimized or a least possible error. Othersoftware programs, in other embodiments, are also used to determine thereduced set of polynomials. In one embodiment, the software program,MATLAB®, generates a set of polynomials that corresponds to the entirerange of engine efficiency loss values with an average error of around 1kilowatt or less. This program completes a least squares fit with thescaled EEL values for a given engine speed, within the operationaltorque limit of that engine speed. In other embodiments, other programswhich provide a least squares fit are used. The finalized reduced set ofpolynomial equations represents the varying relationship between theengine efficiency loss values at different torque and speed conditionsfor the engine. The reduced set of polynomials forms the basis of anengine pattern configured to define the engine operatingcharacteristics.

When reducing the larger set of polynomial equations to the smaller orreduced set of polynomial equations, the polynomial coefficient valuesare adjusted to better represent the EEL values with the now limitednumber of polynomials as determined at block 212. By adjusting thecoefficient values, the reduced set of polynomials reasonably accuratelyrepresents the larger set of polynomial equations and thereforerepresents the manufacturer's engine data. The EEL values for thosespeeds that are no longer included in the pattern definition areinterpolated. Additional modifications to the coefficient values, insome embodiments, are made to maintain the engine data characteristics.Since the reduced set of polynomials includes speed specificpolynomials, a basis for understanding how an EEL pattern shape changesover different speed ranges is provided. The patterns preserve therelationship between EEL values at differing torque and speed points.Once the pattern produced by the polynomials and the EEL pattern onwhich the polynomials are based look similar, the coefficients aredetermined to be finalized for use. Similarity between patterns isdetermined when the average error between the two is sufficientlyreduced to provide desired operating results. Even if the coefficientsare consider to be “finalized”, the coefficient values, in someembodiments, are adjusted at a later time, if real world testing provesthat the pattern is not sufficiently close to the recorded data for thatengine type. The adjusted coefficient values are saved as scalingfactors for use in re-generating engine efficiency loss values at block214.

In other embodiments, a software program, such as the software programknown as MATLAB®, is used to generate a predetermined number ofpolynomials, the number of which is not reduced to a smaller number orreduced set of polynomials. In such a program, the predetermined numberof polynomials is provided before a set of polynomials is determined bythe software program. In another embodiment, the number of polynomialsis determined by the software program to meet a predetermined value ofaccuracy.

Once a final set of polynomials and adjusted coefficient values havebeen determined, a finalized engine pattern for each different type ofengine is provided at block 216. The engine pattern includes thecoefficients of the reduced set of polynomials. In the embodiment ofseven polynomials, a seven by four matrix is provided to represent theway engine efficiency values change with respect to speed and torque forthe given engine across its operating range. The pattern for an enginealso includes at least one scaling factor which is configured torepresent the maximum engine efficiency loss value from the originalengine calculations. A peak torque value from the original engine onwhich the pattern is based for power scaling purposes is also provided.A minimum engine speed and a maximum engine speed from the originalengine on which the pattern is based are for power scaling purposes.

Once an engine has been patterned, each engine is defined by an enginepattern 218, such as pattern 218A, as illustrated in FIG. 6. Pattern218A includes the five definitions of: the reduced set of polynomials,the scaling factors of the EEL values, the peak torque value, theminimum engine speed value, and the maximum engine speed value. One ormore of these patterns are stored in the memory 144 of the transmissionsystem of FIG. 1. For instance, if the transmission to be used in thevehicle is to be used with only one type of engine, then a singlepattern is stored in memory. If, however, a vehicle manufacturer uses asingle type of transmission with different types of engines, in otherembodiments, more than one pattern is stored in the memory 144 toaccommodate the different types of engines.

Once one or more of the engine patterns are stored in the memory 144,the type of engine to which the transmission 118 is connected isidentified to the transmission controller 142. In one embodiment, theengine type is identified in the memory 163 of the engine controller160. Communication between the engine controller 160 and thetransmission controller 142 identifies the engine type to thetransmission controller 142. In another embodiment, the engine type isidentified to the transmission controller 142 as a stored value in thetransmission accessible memory 144. With the identification of theengine type and the storing of the one or more patterns 218, thetransmission controller 142 is configured to operate the transmission118 in an efficient manner.

FIG. 7 is a block diagram 300 of a process to control the operation ofthe transmission 118 using one of the engine patterns 218. Once avehicle is started or while the vehicle is running, a vehicle operatorprovides a throttle command to the engine controller 160 through thethrottle 161. The throttle command is received by the engine controller160 at block 302. Once received, an engine output control command isdetermined based on the throttle command at block 304. In one embodimentthe engine output control command is configured by the controller 160 tocause the engine 102 to develop an output torque at the output shaft 104through a fuel command. The engine controller 160, in differentembodiments, provides other engine control commands based on thethrottle command, such as an engine output torque command or a speedcommand to control the engine output. Any one, some, or all of thesecommands are provided to the transmission controller 142 at block 306.In other embodiments, the transmission controller receives the throttlecommand directly from the throttle.

After the engine command is received by the transmission controller 142,the transmission controller 142 accesses the memory 144 to select astored engine pattern which corresponds to the type of engine 102driving the transmission 116. See block 308. The stored engine patternincludes the reduced plurality of polynomials. Upon receipt of theengine command, the transmission controller 142 determines a new orupdated operating condition of the transmission when compared to thecurrent operating state of the transmission based on the selectedpattern. See block 310. The updated operation condition is determined bythe transmission controller 142 using the contents of the selectedpattern 218 including the reduced set of polynomials. Once the updatedoperating condition is determined, the transmission controller 142compares the updated operating condition to one more limiting operatingconditions which are also available to the transmission controller 142through access to the memory 144 or otherwise at block 312.

The limiting operating conditions define operating conditions of thetransmission which, if determined, would place the transmission in anundesirable operating condition which could damage or otherwise restrictthe efficient operation of the transmission. The transmission controller142 monitors one or more diagnostic responses and conditions to ensurethat a shift occurs when the shift is considered by the transmissioncontroller 142 to be one which does not reduce the operating efficiencyof or damage the vehicle including, but not limited to, thetransmission, the engine, the engine drive shaft, and the vehicledrivetrain. For instance, the following conditions, in differentembodiments, are ones which would not allow a shift to occur: i) if ashift has just occurred and reapplying a clutch again might cause hightemperatures within the clutch that could degrade the life of theclutch, a shift is prevented from occurring; ii) if a shift would applyunacceptable levels of torsional loads on either the engine shaft or thedrivetrain shaft, a shift is prevented from occurring; iii) if a shiftwould force the engine speed to drop too low (below engine idle speed)or if the engine speed would be too high (above the engine high speedgovernor), a shift is prevented from occurring. These conditions are notlimiting and other conditions which prevent shifting are included.

If the determined operating condition is unacceptable, then thedetermined change is not implemented by the transmission controller 142at block 314. In one embodiment, the transmission controller 142provides a fault alert to the operator that the transmission does notaccommodate the desired throttle command. In one embodiment, the faultalert prevents the transmission from changing the current state ofoperation. In another embodiment, the fault alert indicates to the userthat a fault has occurred, but allows the change in operation of thetransmission but at a reduced efficiency operating point.

If, however, the desired throttle command does not put the transmissionin an undesirable state of operation, the transmission controllermodifies the current operating condition of the transmission to theupdated operating condition to move the vehicle at different speed or ina different gear. See block 316.

While exemplary embodiments incorporating the principles of the presentdisclosure have been disclosed hereinabove, the present disclosure isnot limited to the disclosed embodiments. Instead, this application isintended to cover any variations, uses, or adaptations of the disclosureusing its general principles. Further, this application is intended tocover such departures from the present disclosure as come within knownor customary practice in the art to which this disclosure pertains andwhich fall within the limits of the appended claims.

What is claimed is:
 1. A method of controlling the operation of avehicle transmission operatively connected to an engine having operatingcharacteristics and operatively connected to a transmission controlmodule having access to a memory, the method comprising: receiving fuelconsumption data for an engine, wherein the fuel consumption dataidentifies a range of operating characteristics of the engine from aminimum value to a maximum value; converting the fuel consumption datafor the engine to data representative of engine torque data with respectto engine efficiency loss data representative of the engine operatingcharacteristics; generating a set of polynomials to characterize theengine efficiency loss data, wherein the set of polynomials is based ona curve fitting of the engine efficiency loss data and the engine torquedata; storing the set of polynomials in the memory; accessing the set ofpolynomials stored in memory with the transmission control module; andusing the accessed set of polynomials to modify the operation of thetransmission.
 2. The method of controlling the operation of a vehicletransmission of claim 1 wherein the converting the fuel consumption datafor the engine to engine efficiency loss data includes engine efficiencyloss values corresponding to the engine torque data and to engine speed.3. The method of controlling the operation of a vehicle transmission ofclaim 2 wherein the converting the fuel consumption data for the engineto engine efficiency loss data includes determining a range of torquevalues from zero to a maximum torque value, wherein the maximum torquevalue is based on the received fuel consumption data, and a range ofengine efficiency loss values from a range of zero to a maximumefficiency loss value which is based on the received fuel consumptiondata and scaling the torque values to a zero to one scale and scalingthe engine efficiency loss values to a zero to one scale.
 4. The methodof controlling the operation of a vehicle transmission of claim 3wherein the generating a set of polynomials to characterize the engineefficiency loss data includes a generating a set of polynomials tocharacterize the relationship between the scaled engine efficiency lossvalues and the scaled torque values.
 5. The method of controlling theoperation of a vehicle transmission of claim 4 wherein the generating aset of the set of polynomials includes generating the set to include afirst polynomial representing a lowest engine speed, wherein the lowestengine speed is based on the received fuel consumption data, generatinga last polynomial representing a highest engine speed, wherein thehighest engine speed is based on the received fuel consumption data, andgenerating one or more intermediate polynomials representing one or moreintermediate engine speeds between the lowest engine speed and thehighest engine speed.
 6. The method of controlling the operation of avehicle transmission of claim 5 wherein the set of polynomials includesvariables and coefficients and the generating the set of polynomialsincludes modifying a value of one or more of the coefficients to providea set of polynomials having adjusted variables and coefficients tominimize an error between the engine efficiency loss values and the setof polynomials.
 7. The method of controlling the operation of a vehicletransmission of claim 6 wherein the converting the fuel consumption datafor the engine to engine efficiency loss data representative of theengine operating characteristics includes determining a scaling factorrepresentative of a maximum engine efficiency value based on thereceived fuel consumption data and from the engine efficiency loss data.8. The method of controlling the operation of a vehicle transmission ofclaim 7 wherein the converting the fuel consumption data for the engineto engine efficiency loss data representative of the engine operatingcharacteristics includes determining a peak torque value from the engineefficiency loss data.
 9. The method of controlling the operation of avehicle transmission of claim 8 includes determining a minimum enginespeed based on the received fuel consumption data for the engine. 10.The method of controlling the operation of a vehicle transmission ofclaim 9 includes determining a maximum engine speed based on thereceived fuel consumption data for the engine.
 11. The method ofcontrolling the operation of a vehicle transmission of claim 10 furthercomprising: storing the scaling factor, the peak torque value, theminimum engine speed, and the maximum engine speed in the memory;accessing scaling factor, the peak torque value, the minimum enginespeed, and the maximum engine speed stored in memory with thetransmission control module; and using the accessed scaling factor, thepeak torque value, the minimum engine speed, and the maximum enginespeed to modify the operation of the transmission based on the operatingcharacteristics of the engine.
 12. The method of controlling theoperation of a vehicle transmission of claim 1 wherein the generating aset of the set of polynomials includes generating a set of polynomialsincluding at least seven polynomials.
 13. The method of controlling theoperation of a vehicle transmission of claim 12 wherein the generating aset of the set of polynomials includes generating a set of polynomialsconsisting of seven polynomials.
 14. A transmission system configured todrive a drive assembly of a vehicle in response to an engine outputshaft of an engine responding to a throttle command, the transmissionassembly comprising: a transmission including an input configured to becoupled to the engine output shaft and an output configured to drive thedrive assembly; a memory configured to store one or more enginepatterns, wherein each of the one or more stored engine patternsincludes a plurality of polynomials, wherein the plurality ofpolynomials represents the operating characteristics of the engine andis based on a curve fitting of engine efficiency loss data and enginetorque data; and a transmission controller operatively coupled to thetransmission and to the memory, the transmission controller configuredto execute stored program instructions to: determine at least one ofengine speed and engine torque from the received throttle command;determine a current operating condition of the transmission; access thememory to retrieve one of the one or more stored engine patterns;determine an updated operating condition of the transmission using theaccessed engine pattern and the determined at least one of the enginespeed and the engine torque; and modify the current operating conditionof the transmission to an updated operating condition of thetransmission based on the determined updated operating condition of thetransmission.
 15. The transmission system of claim 14 wherein thetransmission controller is further configured to execute stored programinstructions to: determine whether the updated operating condition ofthe transmission is an unacceptable operating condition including one ormore of the following: i) if a shift of the transmission has justoccurred and reapplying a clutch might cause temperatures within theclutch sufficient to degrade the life of the clutch; ii) if a shift ofthe transmission would apply unacceptable levels of torsional loads oneither an engine shaft or a drivetrain shaft; iii) if a shift of thetransmission would force a speed of the engine to drop below an engineidle speed; iv) or if a shift of the transmission would force a speed ofthe engine to exceed an engine speed determined by an engine high speedgovernor.
 16. The transmission system of claim 15 wherein the memory isconfigured to store one or more of the unacceptable operatingconditions, wherein the unacceptable operating conditions prevent ashift of the transmission.
 17. The transmission system of claim 16wherein the transmission controller is further configured to executestored program instructions to: compare the updated operating conditionto the stored one or more unacceptable transmission operating conditionsto determine whether the updated operating condition is an acceptabletransmission operating condition.
 18. The transmission system of claim17 wherein the transmission controller is further configured to executestored program instructions to: not modify the current operatingcondition of the transmission to the updated operating condition if theupdated operating condition is one of the unacceptable operatingconditions; and provide an alert indicating that the updated operatingcondition is one of the unacceptable operating conditions.
 19. Thetransmission system of claim 18 wherein the transmission controller isfurther configured to execute stored program instructions to: modify thecurrent operating condition of the transmission to the updated operatingcondition if the updated operating condition is an acceptable operatingcondition.
 20. The transmission system of claim 19 wherein the storedone or more engine patterns includes a scaling factor of engineefficiency loss values, a peak torque value, a minimum engine speedvalue, and a maximum engine speed value, wherein the minimum enginespeed value and maximum engine speed value are based on a set ofreceived fuel consumption data for an engine.